Heat Exchanger Design and Analysis using OpenFOAM

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Project Overview: In this advanced heat exchanger design project, you will engage in a
comprehensive exploration of heat and mass transfer principles, experimental techniques, computer
simulations, and industry-standard design practices. Each student will work independently to design,
simulate, and analyse a Plate Heat Exchanger using FreeCAD with the OpenFOAM add-in. The
project integrates theoretical understanding, hands-on simulation, and virtual experimentation to
achieve optimal heat exchanger performance according to design standards.
Project Objectives:
1. Demonstrate the ability to identify and solve complex heat and mass transfer problems
individually.
2. Independently design a practical plate heat exchanger using FreeCAD and OpenFOAM.
3. Effectively communicate simulation outcomes through a comprehensive written report submitted
via the Jotform platform and articulate them verbally.
4. Utilise advanced computer skills to simulate heat and mass transfer scenarios using simulation
and design software.
5. Formulate hand calculations and simulation results to optimise the heat exchanger design.
6. Engage in investigative work, simulation analysis, and data interpretation to make informed
engineering decisions.

Sample Solution

Plate Heat Exchanger Design Project

Executive Summary:

This report details the design, simulation, and optimization of a plate heat exchanger using FreeCAD with the OpenFOAM add-in. The project aimed to demonstrate the application of theoretical knowledge, hands-on simulation, and virtual experimentation to achieve optimal heat exchanger performance while adhering to design standards.

Introduction:

Plate heat exchangers (PHEs) are widely used in various industrial applications due to their compact size, high efficiency, and ease of maintenance. This project focuses on designing and simulating a PHE using FreeCAD and OpenFOAM to enhance understanding of heat and mass transfer principles and develop proficiency in computer-aided design tools.

Methodology:

The project followed a structured methodology:

  1. Requirements Definition: Defined the desired performance specifications for the PHE, including heat transfer rate, flow rates, and pressure drops.
  2. Geometry Design: Utilized FreeCAD to design the PHE geometry, including plate dimensions, channel spacing, and baffle arrangement.
  3. Mesh Generation: Generated a computational mesh for the fluid domains within the PHE using the OpenFOAM snappyHexMesh utility.
  4. Numerical Simulation: Defined boundary conditions and thermophysical properties of the fluids in OpenFOAM’s controlDict and thermophysicalProperties dictionaries.
  5. Results Analysis: Analyzed simulation results, including temperature distribution, velocity profiles, and pressure drop across the PHE.
  6. Design Optimization: Performed iterative modifications to the geometry and operating conditions based on simulation results to achieve optimal performance.

Design and Simulation:

The initial design of the PHE was based on the specified heat transfer rate and flow rates. The geometry was optimized through iterative simulations to achieve a balance between heat transfer efficiency and pressure drop. The final design utilized a corrugated plate configuration with optimized baffle spacing to promote turbulence and enhance heat transfer.

Results and Discussion:

The simulation results provided valuable insights into the internal flow characteristics and thermal performance of the PHE. The analysis revealed the temperature distribution within the plates, velocity profiles in the fluid domains, and pressure drop across the exchanger. The results were compared with hand calculations to validate the simulation methodology.

Optimization and Conclusion:

Based on the simulation results, the PHE design was further optimized to improve its performance. The final design achieved the desired heat transfer rate with minimal pressure drop, demonstrating the effectiveness of the iterative design and simulation approach.

Recommendations:

Further optimization could be explored by varying the plate materials, investigating different baffle configurations, and implementing advanced turbulence models. Additionally, incorporating a cost analysis and environmental considerations would provide a more comprehensive evaluation of the PHE design.

Overall, this project successfully demonstrated the application of heat and mass transfer principles, computer-aided design tools, and computational simulation techniques in the design and optimization of a plate heat exchanger. The project provided valuable insights into the complexities of heat transfer processes and fostered a deeper understanding of industry-standard design practices for PHEs.

Additional Notes:

  • The report should include detailed information about the design specifications, geometry, simulation results, and optimization strategies.
  • Include relevant figures, tables, and graphs to visually represent the design and simulation data.
  • Clearly explain the assumptions and limitations of the simulation model.
  • Provide a comprehensive discussion of the results and their implications for the performance of the PHE.
  • Formulate clear and concise conclusions and recommendations for further research or design improvements.

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